DE102011118784A1 - Rolling profiled bending method for manufacturing variable geometry profile components in automobile sector, involves concatenating shaping modules that exhibit technical functions such as reaction force absorbing function - Google Patents

Abstract

The method involves positioning modular shaping modules relative to each other, where the shaping modules comprise two operation stages that comprise a common tool carrier. The shaping modules are concatenated, where the modules realize different technical functions such as reaction force absorbing function, a profile guiding function, a profile cross-section producing function, a profile feeding function and a profile bending function. The operation stages are formed from driven roller tools or surface structure tools.

Description

The invention relates to a manufacturing method for producing geometrievariable profile components. In the automotive sector, new customer requirements, legal framework conditions and new technology trends are creating a high pressure to innovate, which is accompanied by high global cost pressure. On the one hand, comfort, safety, driving performance, technology and individuality on the one hand are more and more in line with the requirements for economy, reliability and environmental friendliness on the other.

In the course of electromobility, the trend in car body shell construction is evolving from simple profiles to complex profile structures, which have increasingly variable geometric features.

The variable geometry features are cross-sectional changes over the component length, wall thickness profiles in the transverse and longitudinal direction and variable, three-dimensional curvature curves along the profile longitudinal axis.

Such closed geometrically variable profile components are already being produced in multi-stage, sequential manufacturing processes such as hydroforming.

In the field of open profiles, process combinations of roll forming and bending technology are likewise known for setting variable profile geometries.

State of the art

From the publications DE 102 005 000 893 A1 and DE 000 0190 7440 5210 A1 are known process combinations of roll forming and three-roll bending process. In the roll forming process, the profile cross section is initially set, which receives a variable curvature in the subsequent bending operation. Such components have a constant cross-section and a variable longitudinal geometry.

From the patent US 020 080 264 509 A1 For example, a method is known in which, after roll profiling and forming the final geometry, the profile is bent on stationarily positioned flexures before the end turn is adjusted in a freely positionable flexure. The component has a constant cross section with a variable curvature over the component length.

From the patent application EP 000 002 279 806 A1 a method based on the roll forming technique is known in which on the machine bed horizontally movable profiling stitches longitudinally variable geometry profile components produce with a constant cross-section.

In the patent application DE 102 005 031 437 A1 the roll forming operation is substituted by a slide pull operation. Here too, longitudinally variable geometry profile components with a constant cross section can be produced

The listed production methods for open profile components are generally characterized in that the bending operation is always followed by the roll forming operation. Accordingly, a constant profile cross section is further transformed.

Disadvantage of these method arrangements is that the components have a variable longitudinal geometry but no variable cross-section and thus do not meet the present and future requirements for the features for geometry-variable profile components.

task

The object of the invention is to provide a production method which produces open, geometry-variable profile components by producing variable longitudinal geometries (bending, curvature) as well as variable cross-sectional geometries (profile cross section) over the component length.

This object is achieved by a modular Rollzprofilierbiegeverfahren.

For this purpose, the subject matter of the invention provides for a break-up of the previous sequential method arrangement of roll profiling in such a way that a bending station is integrated after each cross-section-changing forming operation.

This integral combination of cross-section forming stage and bending stage is constructed such that a uniform, modular forming module is formed, which forms the roll profiling bending process by linking several modules.

An advantage over the previous manufacturing methods lies in the production of open profile components with variable transverse and longitudinal geometries. Furthermore, rollforming bending is a modular and therefore very flexible production concept, in which the component geometry can be largely generated by adjustable process parameters.

Further advantages result from the use of the broad knowledge in both the roll forming and in the bending technology, such as inline welding, flanging, stamping, crimping, or Trimming operations and the use of a wide range of materials, from ultra-high-strength steels to aluminum and fiber-reinforced thermoplastics.

Showing:

1 shows a side view of a modular Rollzeilier bending module based on roller tools with minimal tool configuration.

2 . 3 and 4 show in a side view further, but not exhaustive in the list of embodiments of modular Rollzprofilierbiege modules based on roller tools

5 shows in a side view of a modular Rollzprofilierbiege module based on roller tools with a positioned on the profile sheet inside support role.

6 shows a side view of a modular roll forming bending module based on a combination of roll and surface contour tools.

7 . 8th and 9 show in a side view further, but not exhaustive in the list embodiments of modular Rollzprofilierbiege modules based on a combination of roller and surface contour tools.

10 shows in a sectional view by way of example a machine configuration of Walzprofilierbiegeprozesses consisting of successively connected WPB modules

11 shows in a 3D representation by way of example a construction of a machine configuration for the Walzprofilierbiegen consisting of successively connected WPB modules

12 shows in a 3D representation by way of example an open geometrically variable profile component, which can be produced in the roll forming bending process.

13 shows in a 3D representation of an example made in Walzprofilierbiegeverfahren geometrically variable, multi-section profile component with open and closed over the component length profile cross-sections.

The roll forming module in 1 is made up of five roller tools. The upper and lower profiling rollers ( 12 ) 13 ) are arranged one above the other as in a roll forming stand and form a profiling stitch. The profiling stitch is preceded by a support arranged in the opposite direction of curvature. 11 ) and subsequently a bending roller ( 14 ). The function of the profiling stitch is in addition to the transformation of the incoming cross-sectional geometry, the transmission of the feed to the profile component ( 15 ). The support roller absorbs the reaction force generated during bending and feeds the profile to the profiling stitch. It has a tool contour corresponding to the semifinished product cross-section. The bending roller directs the profile on a curved path, which sets a lasting component longitudinal curvature when material plastification reaches. Since no change in cross section is to take place at this position, it has the same tool contour as the upper profiling roller.

For bending a profile ( 21 ) in two directions of curvature, the roll profiling bending module is as in 2 around a lower support ( 23 ) and a lower bending roller ( 26 ) expanded. The upstream support rollers ( 22 ) 23 ), the profiling rollers ( 24 ) 25 ) and the bending rollers ( 26 ) 27 ) each form an operation stage (OP).

Accordingly, a roll profiling bending module is characterized by at least three operational stages OP1 (FIG. 22 ) 23 ), OP2 ( 24 ) 25 ) and OP3 ( 26 ) 27 ), which are equipped in total with at least four roller tools. All operation levels fulfill the technical functions "Support profile", "Create profile section", "Drive profile" and "Bend profile" at least once.

For this it is necessary for the first and second OPs to be mounted in the profile feed direction at least rotationally about the Z axis. Furthermore, the last OP has at least one translatory degree of freedom. The geometry complexity of the profile component increases with increasing number of degrees of freedom per OP.

embodiments

Further advantageous embodiments of rolled profiling bending modules show 3 . 4 and 5 , Across from 1 can with ( 31 ) 32 ) 33 ) 34 ) out 3 two cross-section altering operations are performed. The bending operation takes over ( 35 ). However, a right-left bend is like in 2 not possible.

This option is offered by the module 4 , In addition to 2 in which only two cross-sectional changes ( 22 ) 23 ) such as ( 24 ) 25 ) are possible at 4 three cross-cutting operations ( 41 ) 42 ) such as ( 43 ) 44 ) and ( 45 ) 46 ) be performed. In addition, with ( 45 ) 46 ) a right-left bending operation. Support ( 41 ) and ( 42 ) the profile and transmit together with ( 43 ) 44 ) 45 ) 46 ) the profile feed.

Since the profile falls in the bending radius at a high strip tension, another roll ( 57 ) as in 5 support the inner arch of the profile.

In addition to the role-based tool concepts, the technical functions "supporting the profile", "creating the profile cross-section" or "profile bending" can also be realized by other solution mechanisms. Thus, a slidable die can fulfill both the function "support profile", "create profile cross section" and "bend profile". Furthermore, a stamping tool could implement the technical functions "support profile", and "bend profile".

The WPB module in 6 is made of two stamps ( 61 ) 64 ) and a cross-sectional profiling ( 62 ) 63 ), which also provides for the profile feed. The stamp positioned at the infeed ( 61 ) realizes the function "support profile" and after profiling stitch ( 62 ) 63 ) arranged stamps ( 64 ) the function "profile bend".

embodiments

Building on this basis, the 7 . 8th and 9 but not by way of example in the enumeration further Walzprofilierbiege modules, which consist of profiling and flat contour tools and all realize the technical functions "profile support", "profile cross section", "profile" and "profile bend" realize their own way.

The construction of the WPB module in 7 consists of a profiling stitch ( 72 ) 73 ) upstream surface contour tool ( 71 ) and a downstream bending punch ( 74 ). Together they fulfill the technical functions listed above.

The module in 8th has the same tool composition, but m at different stages of operation. Here the stamp realized ( 83 ) the function "profile support", while the profiling stitch ( 84 ) |, ( 85 ) transmits the profile feed and initiates the bending moment.

9 shows an additional bending punch ( 95 ) extended module 7 to make right-left bends.

A schematic representation of a roll forming bending system with WPB modules connected in series shows by way of example 10 , The process chain shown consists of three WPB modules ( 101 ) 103 ) 104 ) and has bending stages in OP-3, OP-5 and OP-7. On the other hand, the OP-1, OP2, OP-4, OP-6 shape the cross-sectional geometries of the profile. If the profile reaches its final length ( 105 ) in the area OP-7, the feed stops and the system moves completely open. With the help of a cutting tool, the profile component is moved to the position ( 102 ) separated.

The longitudinal geometry of the profile has two opposite spatial bending radii, which merge into a straight profile area. Depending on the design of the profiling operation stages, the course of the transverse geometry has three or more cross-sectional shapes and corresponding transition regions.

embodiment

11 show by way of example, but not conclusively in the illustration and embodiment, three rolling profiling bending modules connected in series ( 112 ), which are supported on tool carrier plates ( 111 ) are mounted. For spatial positioning, they can be positioned in space by robots or parallel kinematic machines, for example.

In a further exemplary but not conclusive embodiment for open geometry variable profile components shows 12 a profile in which over the component length a U-shaped output cross-section ( 121 ) in a hat-shaped profile cross-section ( 122 ) and thereby two opposing bends ( 123 ) 124 ) having. The contour at the end of the profile ( 125 ) has just been formed.

In a further advantageous embodiment of the method invention described is a mult-section profile component in 13 exemplified. This has over the component length in addition to variable bending radii ( 136 ) 137 ) 138 ) both open profile cross sections ( 131 ) as well as closed cross sections ( 133 ) over a transitional area ( 132 ) 134 ) are interconnected.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102005000893 A1 [0006]
• DE 000019074405210 A1 [0006]
• US 020080264509 A1 [0007]
• EP 000002279806 A1 [0008]
• DE 102005031437 A1 [0009]

Claims (6)

Roll profiling bending process for the production of geometrically variable profile components, characterized in that it consists of a concatenation of modular forming modules, each of which the technical functions "take reaction force", "profile", "profile cross section", "profile feed generate" and "profile turn "realize at least once. Roll profiling bending process for the production of geometrically variable profile components, according to claim 1, characterized in that the concatenation consists of at least two forming modules, which are positioned to each other. Roll profiling bending process for producing geometrically variable profile components, according to claim 1, characterized in that each forming module has at least two stages of operation. Roll profiling bending process for producing geometrically variable profile components, according to claim 1, characterized in that the operation stages have a common tool carrier. Roll profiling bending process for the production of geometrically variable profile components, according to claim 3, characterized in that at least one of the operational stages consists of driven roller tools. Roll profiling bending process for the production of geometrically variable profile components, according to claim 3, characterized in that the further operation stages consist of roller tools or surface structure tools.

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